Sustainable denim fabric development using jute-cotton blends: a viable strategy to reduce cotton consumption

Abstract

Purpose This study aims to develop sustainable denim fabric by reducing cotton consumption through the use of cottonized jute–cotton blended yarn (Jutton) in the weft direction, while maintaining 100% cotton yarn in the warp, without compromising fabric performance. Design/methodology/approach Jutton yarns with three cotton-to-jute blend ratios (90:10, 80:20 and 70:30) were produced and woven into denim fabrics on an industrial air-jet loom. The fabrics were evaluated for moisture management, thermal behavior, breathability, hand feel and tensile performance using standard testing methods. Findings Increasing jute content resulted in higher yarn irregularities, surface fuzziness and fabric stiffness, along with reduced tensile strength. However, fabrics containing up to 30% jute demonstrated acceptable absorbency, thermal insulation, tactile properties, air permeability and water vapor permeability. Despite slight reductions in softness and stretch, overall functional integrity and durability were maintained, indicating suitability for eco-friendly winter-wear denim applications. Originality/value This study presents a novel and industrially viable approach to incorporating jute into denim production through selective weft integration, offering a sustainable strategy to reduce cotton dependency while preserving key textile performance attributes.